Shrink wrap material and method for protecting articles

ABSTRACT

A method and material for shrink wrapping articles includes wrapping the article with a shrink wrapping material having a shrink/stretch film outer layer and an inner layer of a non-woven fabric. The shrink/stretch film responds to heat by shrinking around the article being wrapped, while the non-woven material aerates to form bubbles thus acting as a cushion between the shrink/stretch film outer layer and the article being wrapped. Accordingly, the article being wrapped is protected during the shrinking process, and is also protected from hurled objects while the article is being transported. The non-woven layer may be treated with chemical additives to control the environment in which the article is wrapped and/or to indicate tampering.

This invention relates to a shrink wrap material and a method forprotecting articles by wrapping them in the shrink wrap material.

Large articles, such as automobiles, vans, machinery and boats oftenmust be transported from the factory to the customer on open truckswhere they are exposed to the elements. Customers expect that newvehicles, machinery, and other large articles to be in pristinecondition when they are delivered, and will not tolerate flaws, even ifsuch flaws are no fault of the manufacturer and have occurred after thearticle has been shipped from the factory. Damage may be caused by anynumber of factors. For example, acid rain is an increasingly commonphenomena, and, if the acid rain is of sufficient concentration, damagedpaint may occur. Furthermore, open transport of such articles subjectsthe articles to damage due to small rocks and stones which may be hurledagainst the article during transportation. One way to protect even largearticles from the environment is through shrink wrapping, which is mostcommonly employed on very small household articles. A method of shrinkwrapping automotive vehicles is disclosed in U.S. Pat. No. 3,653,497.

However, it is difficult to shrink wrap large articles, such asvehicles, machinery or boats. When the shrink wrap film is heated duringshrinking, it becomes very vulnerable. Accordingly, holes are oftenpulled in the shrink wrap film as the latter is applied over the vehicleor other large object. Furthermore, the shrink wrap film itself isabrasive and can damage paint when the shrink wrap film is applied to anarticle.

According to the present invention, a two layer shrink wrap materialincludes a shrink/stretch film as the outer layer, and an inner layercomposed of a non-woven fabric consisting of randomly arranged,non-woven fibers which cooperate to define voids. Accordingly, the innerlayer is a soft fabric, which acts as a cushion that supports theshrink/stretch film away from the paint. When the shrink/stretch film isshrunk around the article, the non-woven layer aerates to form bubbles,thus further softening the non-woven fabric. The aeration is due to thedifferential shrink response between the shrink wrap and the non-wovenfabric, and is also a result of heating the shrink film to causeshrinkage, which also causes the air entrained within the non-wovenfabric to expand, thus causing formation of bubbles to further softenthe material. Because of the cushioning effect of the non-woven fabric,the stretch of the shrink film is limited to a comparatively small area,thus substantially reducing the chance that the shrink film will ruptureas it is applied. After the material is shrunk around the article, thematerial retains its elasticity, again due to the cushioning effect ofthe non-woven inner layer, so that the material resists rupture if it isstruck by hurled objects, such as rocks and stones. Accordingly, animportant advantage of the present invention is that an improved shrinkwrap material protects large objects during the shrink wrapping processitself and also resists environmental contaminants and hurled objectsafter the material is shrunk around the article.

Still another important advantage of the present invention is that thenon-woven layer may be treated with additives, such as acids, acidneutralizers, anti-fogging agents, microbial agents, antioxidants,antistats, UV stabilizers, hydrophilic and/or hydrophobic surfacants,and many other chemicals to thereby control the environment around thearticle protected by the material of the present invention. Furthermore,tampering can be indicated by applying an air reacting color agent tothe non-woven layer. Accordingly, if the outer shrink film is punctured,a color change in the non-woven fabric will immediately indicatetampering. The shrink material according to the present invention may,however, be made to "breathe" if desired by providing perforations inthe outer shrink film.

These and other advantages of the present invention will become apparentfrom the following description with reference to the accompanyingdrawings, in which:

FIG. 1 is schematic illustration of the manner in which the shrinkwrapping material according to the present invention is manufactured;

FIG. 2 is a cross sectional view taken through the shrink wrappingmaterial according to the present invention before the material isshrunk around an article;

FIG. 3 is a cross sectional view similar to FIG. 2 but illustrating theshrink wrapping material according to the present invention after it isshrunk around an article;

FIG. 4 is a cross sectional view illustrative of the manner in which theshrink wrapping material illustrated in FIG. 2 is rolled together withthe non-woven fabric sides of the material facing one another, so thatthe material can be formed into a bag fitting around an article to beprotected;

FIG. 5 is a perspective view of a military missile which is wrappedusing the shrink wrapping material made according to the presentinvention;

FIG. 6 is a perspective view of a bale of hay which is wrapped using thematerial according to the present invention;

FIG. 7 is a perspective view of an automotive vehicle which is to beprotected by the shrink wrapping material according to the presentinvention; the vehicle is illustrated after the material is placed onthe vehicle but before shrinking; and

FIG. 8 is a perspective view of a motorcycle protected by the shrinkwrap material made pursuant to the present invention.

Referring now to FIGS. 2-3 of the drawings, a shrink wrap materialgenerally indicated by the numeral 10 made according to the presentinvention includes a layer 12 consisting of a shrink/stretch film whichhas a predetermined shrink response in response to heat applied to thefilm and a second layer 14 which is secured to the layer 12 as will behereinafter described. The second layer 14 is a non-woven fabriccomprising non-woven, randomly arranged fibers. The first layer 12 maybe of any known type of shrink/stretch films well known to those skilledin the art, but is preferably a polyolefin in the ethylene vinyl acetatecopolymer family. However, other shrink wrap films may be used. Thenon-woven fabric 14 may be of any well known type, and may include bothnatural and man-made fibers, or combinations thereof, such as polyester,nylon 6, 6 or a combination of wood pulp and polyester fibers. Typicalfabrics are sold by the Dupont Corporation under the trademark Sontara®or by Fabreweb North America, Inc., identified as fabric PBN-2. Thenon-woven fabric may be spun bonded. It will be noted that the fibersforming the non-woven fabric 14 cooperate to define voids 16.Accordingly, the upper and lower surfaces of the non-woven fabric 14 areirregular. As will hereinafter be explained, an adhesive is applied tothesurface of the fabric 14 that will be bonded to the film 12.Accordingly, the adhesive is applied only to the raised portions of thefabric 14, and does not wet through the bat. Accordingly, the non-wovenfabric 14 is not continuously bonded to the film 12, but only the raisedportions of the fabric 14 are bonded to the film 12, thus creatingdiscontinuities in the bond, such that only a relatively smallpercentage of the surface area of the fabric 14 is secured to the shrinkfilm 12. This permits the non-wovenfabric 14 to aerate during theshrinking process, thus permitting the non-woven fabric 14 to act as acushion between the shrink film 12 and thearticle being wrapped. Theaeration of the non-woven fabric 14 is due to the fact that the heatapplied to shrink the material 10 around the article being wrappedcauses air entrained in the voids 16 to expand, thussubstantiallyincreasing the size of the voids. Formation of the larger voids orbubbles is also due to the fact that the fabric 14 has a differentshrink response than does the shrink film 12. Although the film 12shrinks in response to heat applied thereto, the non-woven fabric 14 mayeither remain about the same size or increase in size to expand thevoids in response to the applied heat. Since heat applied to shrink thefilm 12 may approach 400° F. during the shrinking process, it isimportant that the material from which the non-woven fabric 14 ismanufactured be able to withstand such temperatures.

It is also important that the fibers comprising the non-woven fabric 14be able to reflect and/or absorb the majority of the heat. Accordingly,the article being wrapped is protected from the heat applied to shrinkthe material 10. Less heat is required to shrink the material 10, sincethe fibers of the fabric 14 reflect heat back into the shrink film 12,thus reducing the amount of heat that must be applied to the shrink film12 in order to effect shrinkage. Since, as will be discussed laterherein, it isdesirable to apply chemicals to the non-woven fabric 14 tothereby either control the environment of the article being wrapped orto treat the article being wrapped, it is important that the fibers fromwhich the fabric 14 is formed are both highly chemical resistant andinert.

The adhesive applied to the non-woven fabric 14 is preferably a rubberthermoplastic hot melt adhesive in the "block copolymer" family. Any oneof several compounds well known to those skilled in the art may be usedwith equal effectiveness. It is important that the adhesive be of aconsistency that does not wet through the fabric 14, yet can be easilyapplied to the raised portions of the surface of the fabric 14 which isbonded to the shrink film 12. Because the adhesive is a hot melt, it istacky when applied to the fabric so that a good stick is obtained whenthefabric 14 and the film 12 are merely touched together, and nopressure needbe applied to obtain bonding. Pressure would compress thenon-woven fabric 14, which is obviously undesirable.

Referring now to FIG. 1, the film 12 is fed from a roll 18 and thenon-woven fabric 14 is fed from a roll 20. Fabric 14 is fed through agluing station 22 where the hot melt adhesive is applied lightly to theupper surface of the fabric 14 as it is fed toward the bonding station22.Bonding station 22 gradually reduces the distance between the fabric14 andthe film 12 as these materials are carried through the bondingstation 22. The bonding station 22 is adjusted such that the film 12 isbrought into touching engagement with the fabric 14 without substantialpressure being applied to either the film 12 or the fabric 14. Asdescribed above, since the adhesive using a hot melt adhesive and isvery tacky, this touching ofthe film 12 against the non-woven fabric 14is all that is required to secure the film to the fabric, it being notedthat the bonding will only take place across a relatively smallpercentage of the fabric 14 and film 12, since the adhesive is appliedonly to the raised portions of the fabric 14 and does not wet throughthe fabric 14. After passing through the station 22, the material iswound on a roll 24.

Referring to FIG. 4, the shrink wrapping material 10 from two rolls 24are unwound from the rolls 24 and then rewound on another roll, with thenon-woven fabric 14 of the layers wound facing one another as indicatedinFIG. 4. Accordingly, a section comprising two layers of the material10, with the fabric layers 14 facing one another, may be unwound fromthe roll, an appropriate amount cut off, and the edges are sealed toform a bag in which the non-woven fabric 14 is on the inside of the bagand the shrink film 12 is on the outside of the bag. As illustrated inFIG. 7, thebag 26 of the material thus formed is placed over anautomotive vehicle 28 which is to be wrapped by the material 10. Heat isthen applied to the bag26 to shrink the bag around the vehicle 28. Heatmay be applied either through a conventional heating tunnel, in the caseof high volume production, or by the use of hand held blowers, in whichone or more workmen with a blower walk around the van 28 to apply heatto the bag 26, thereby causing the latter to shrink into contact withthe van 28.

As discussed above, as the bag is heated, the non-woven layer 14, whichforms the inside of the bag 26, aerates to form bubbles, thus expandingthe non-woven fabric 14 so that it softens and acts as a cushion,maintaining the film 12 away from the article being wrapped. Since thefabric 14 is extremely soft, it will not damage paint, and thecushioning provided by the fabric causes the material 10 to resistpuncture by hurledobjects such as stones or rocks during transport ofthe vehicle 28 to the consumer. Furthermore, during the shrinkingprocess, the film 12 is extremely vulnerable to rupture, since the heatapplied during shrinkage weakens the film. Accordingly, it is difficultto apply prior art materials to large objects since the stretching forceapplied to the film may be transmitted over a large area and may rupturethe film. However, the cushioning provided by the non-woven fabric 14 ofmaterial 10 limits application of the stretching forces during shrinkageto a relatively small area, thus reducing the chance that the shrinkfilm 12 will rupture.

Referring now to FIG. 8, other articles, such as a motorcycle 30, mayalso be wrapped using the material and method of the present invention.When motorcycle 30 is wrapped, the bag 32 is cut to size to fit over themotorcycle 30, and then shrunk into engagement with the motorcycle 30,thus providing protection for the motorcycle 30 during transport. Asdescribed above, any other article which is subject to damage duringtransport, particularly large articles, may be wrapped using thematerial and process of the present invention. In addition to automotivevehicles and motorcycles, lawn and garden equipment, boats and largemachinery may also be wrapped.

Referring to FIG. 5, a military product, such as a missile 34, isillustrated wrapped by the material 10. Obviously, the performance ofmilitary products, such as the missile 34, may be affected if damage tothe paint occurs, since even small defects in the paint may cause theflight path of the missile 34 to be changed. Furthermore, it isimportant to safeguard military products from tampering and sabotage,and to be ableto know if such tampering or sabotage has occurred.Accordingly, the non-woven fabric 14 of the shrink wrap material 10 usedto wrap the military product 34 is treated with a known air activatedcolor change material. Accordingly, if the film 12 is punctured, thecolor change material will be activated, thereby immediately notifyingof a punctured outer layer, so that tampering of the military missile 34will be indicated. Other chemical additives may be used to treat thefabric 14, such as chemicals to control the humidity within the envelopeformed by the material 10, UV stabilizers to prevent sunlight damage toproducts wrapped by the material, and acid or acid neutralizers, tocontrol the acidity of the environment.

Referring to FIG. 10, an agricultural product, such as a bale of hay 36,may also be wrapped by the material 10. Most agriculture products, suchashay, degrade quickly, generally must be used near where the product isproduced, and generally cannot be exported. Accordingly, by wrapping thebale of hay 36 with the material 10, the environment can be controlledto maintain freshness of the product. For example, anti-fungal agentsmay be added to the material 14 and other additives may be added tocontrol the humidity to which the product 36 is maintained. Of course,the outer layer12 can be made air permeable by punching holes in thematerial, if such is desired.

Accordingly, the shrink wrapping material 10 may be used to wrap a largevariety of both large and small articles. The shrink wrap material 10not only protects the article being wrapped from the abrasive effect ofthe outer film 12 as the article is being wrapped, but also protects thearticle from environmental conditions, such as rain, mud or hurledobjects. Both large and small articles may be wrapped with the materialand then transported without damage to the article. Furthermore, theinnerlayer may be treated to control the environment in which thewrapped article is maintained, and also may be treated with materialthat will indicate tampering.

I claim:
 1. A material for shrink wrapping articles comprising ashrinkable, stretchable film first layer having a predetermined shrinkresponse in response to heat applied to the film and a non-woven fabricsecond layer having raised and lowered portions, each of said first andsecond layers having surfaces engaging one another wherein said raisedportions of said second layer form a surface of the fabric that bonds tothe film surface by an adhesive to form intermittent bonds between thelayers, said intermittent bonds being distributed across the engagingsurface of the film.
 2. Material for shrink wrapping articles as claimedin claim 1, wherein said second layer has a shrink response in responseto heat that is different from the shrink response of the first layer.3. Material for shrink wrapping articles as claimed in claim 1, whereinsaid non-woven fabric includes randomly arranged fibers.
 4. Material forshrink wrapping articles as claimed in claim 1, wherein said secondlayer defines an irregular surface defined by raised and loweredportions, having an adhesive applied to said raised portions withoutwetting through said fabric, said first layer being bonded to saidraised portions by said adhesive to form said intermittent bond betweenthe second and first layers.
 5. Material for shrink wrapping articles asclaimed in claim 1, wherein said second layer is made of fibers, atleast some of said fibers being heat reflective to the first layer andto assist in shrinking the first layer by reflecting heat back into thefirst layer.
 6. Material for shrink wrapping articles as claimed inclaim 5, wherein said fibers are randomly arranged to form a non-wovenfabric.
 7. Material for shrink wrapping articles as claimed in 1 whereinsaid second layer includes randomly arranged fibers forming saidnon-woven fabric, having fibers defining voids filled with air, saidfabric having an irregular surface for bonding with the first layer. 8.Material for shrink wrapping articles as claimed in claim 1 therein saidsecond layer includes randomly arranged fibers forming said non-wovenfabric, said fibers defining voids filled with air.
 9. A method ofmanufacturing a material for shrink wrapping articles comprising thesteps of providing a shrinkable, stretchable film, providing a quantityof a non-woven fabric of randomly arranged fibers defining voids, saidfabric including an irregular surface which engages said film on asurface thereof, said surface of the fabric being defined by raised andlowered portions, said method including the steps of applying anadhesive to said raised portions only without wetting said fabric withsaid adhesive and bonding said fabric to said film via said adhesive toform intermittent bonds distributed across the engaged surfaces of thefabric and film without substantially compressing said fabric. 10.Method of manufacturing material as claimed in claim 9, wherein saidmethod includes the step of bringing the raised portions of the fabricinto engagement with the film without pressing the film and the fabrictogether.
 11. Method of manufacturing material as claimed in claim 10,wherein said method includes the steps of placing the fabric side of onelayer of said material against the fabric side of an adjacent layer ofmaterial and then sealing around a predetermined perimeter of thematerial to form a bag having said fabric on the inside of the bag andsaid film on the outside of the bag.